SEPARATOR
SIZING
Theory and Calculation
SEPARATION THEORY
Gas/Liquid Separation Theory
Liquid droplet settling
Liquid drops separated from gas phase when its
velocity reach terminal (settling) velocity
Terminal velocity when Drag Force = Buoyant Force
Drag Force depends on Drag Coefficient CD
Re < 10 24
CD
Re
24 3
Re > 1000 CD 1 / 2 0.34
Re Re
Cont.
Terminal velocity equations for different conditions
1.78 106 S .G.d m
2
Re < 10 Vt
1/ 2
l g dm
Re > 1000 Vt 0.0199
C
g D
The value of CD is estimated and then used in the
calculation of gas capacity constraint
Cont.
But in production facility, flow almost always has Re >
1000. So how to find CD ?
Start with Re >>1000 so that CD ~ 0.34
Use CD = 0.34 to calculate Vt
Use Vt to calculate Re
Use Re to calculate new CD
Repeat process until CD values beginning to be the same
Use this latest CD value in the gas capacity equation
Cont.
Liquid retention time
Retention time is average time a liquid molecule is
retained in vessel
To ensure liquid and gas reach equilibrium so that gas
molecule can evolve from liquid phase
Retention time = Volume of liquid storage in vessel
Liquid flow rate
Usually 1 to 3 minutes
Oil/Water Separation Theory
Oil drop/water drop settling
Flow around oil drops in water or water drops in oil is
laminar so water droplets fall at their terminal velocity
Oil/water retention time
Need certain amount of oil storage so that oil reaches
equilibrium, entrained gas liberated, and free water
coalesced to fall into water storage
Need certain amount of water storage for entrained large
droplets of oil have time to coalesce and rise to oil-water
interface
Retention time 3 30 minutes
SEPARATOR SIZING:
TWO-PHASE SEPARATOR
General sizing procedure
CALCULATE
1. Gas capacity constraint
Minimum vessel diameter OR Relationship between diameter
and effective length that satisfy gas capacity constraint
2. Liquid capacity
Relationship between diameter and effective length OR height
that satisfy liquid capacity constraint
3. Seam-to-seam length, Lss
For Gas capacity and Liquid capacity
4. Slenderness ratio
For each Lss calculated
SELECT reasonable vessel size (diameter and length)!
VERTICAL SEPARATOR
Gas outlet
Mist extractor
Gas capacity
Inlet
Seam-to-seam Length Lss
Liquid capacity Height h
Liquid Outlet
Diameter d
Vertical separator sizing procedure
1. Determine CD using iterative procedure
2. Calculate d for gas capacity constraint using
1/ 2
TZQg g CD
d 5040
2
P l g d
m
3. Calculate d2h for liquid capacity constraint
tr Ql
d h
2
0.12
Cont. vertical
4. Set retention time tr to be 1, 2 and 3 minutes
(usual case)
5. For each tr , calculate and tabulate values of
a) d
b) h
c) Lss
h 76
OD < 36 Lss
12
OD > 36 h d min 40
Lss
12
d) Slenderness Ratio (SR), (12)Lss/d
Cont. vertical
From table, select possible choices of separator size
(d x Lss) based on the values of (12)Lss/d
Select (12)Lss/d values range 3 4
d values must be greater than the calculated minimum
vessel diameter for gas capacity constraint (Step 2)
Your final selection should be based on your
judgment on the costs of each possible separator
Example of separator selection
Possible size
36 x 10
30 x 10
30 x 10 or
30 x 8
HORIZONTAL SEPARATOR
Seam-to-seam Length Lss
Gas outlet
Gas capacity (50%)
Gas-oil interface
Diameter d
Liquid capacity (50%)
Inlet Liquid Outlet
Effective Length Leff
Gas molecule flowing at average gas velocity, Vg
Liquid droplet dropping at settling velocity Vt relative to gas phase
Horizontal separator sizing procedure
1. Determine CD using iterative procedure
2. Calculate dLeff for gas capacity constraint
TZQg g CD
1/ 2
dLeff 420
d
P l g m
3. Calculate d2Leff for liquid capacity constraint
t r Ql
d Leff
2
0 .7
Cont. horizontal
4. Set retention time tr to be 1, 2 and/or 3 minutes
(usual case)
5. For each tr , calculate and tabulate values of
a) d
b) Leff for
Gas capacity from equation Step 2
Liquid capacity from equation Step 3
Cont. horizontal
c) Lss for
d
Gas Capacity Lss Leff
12
4
Liquid capacity Lss Leff
3
d) Slenderness ratio (SR), (12)Lss/d
Cont. horizontal
From table, compare the values of Leff for each gas
and liquid capacity that governs the design of the
separator
The one with larger required length governs
Then, select possible choices of separator size
(d x Lss) based on the values of SR
Select SR values range 3 5
Lss values selected are the one that governs the design
Example of separator selection
Use the liquid Lss values
to select separator size
Horizontal Separator Example
Diameter vs. Length
Liquid Liquid
tr d Gas Leff Leff Gas Lss Lss SR
Possible size
16 2.5 33.5 44.7 33.5
20 2 21.4 28.5 17.1
24 1.7 14.9 19.9 9.9
3 30 1.3 9.5 12.7 5.1
36 1.1 6.6 9.1 3 36 X 10
42 0.9 4.9 7.4 2.1
48 0.8 3.7 6.2 1.6
Liquid capacity constraint governs since it has the largest required length
Thats basically it.
